Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K9/00—Use of pretreated ingredients
  • C08K9/04—Ingredients treated with organic substances
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K9/00—Use of pretreated ingredients
  • C08K9/08—Ingredients agglomerated by treatment with a binding agent
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
  • C08J5/046—Reinforcing macromolecular compounds with loose or coherent fibrous material with synthetic macromolecular fibrous material
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
  • C08J5/06—Reinforcing macromolecular compounds with loose or coherent fibrous material using pretreated fibrous materials
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K7/00—Use of ingredients characterised by shape
  • C08K7/02—Fibres or whiskers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L101/00—Compositions of unspecified macromolecular compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L79/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen or carbon only, not provided for in groups C08L61/00 - C08L77/00
  • C08L79/02—Polyamines
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D179/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen, with or without oxygen, or carbon only, not provided for in groups C09D161/00 - C09D177/00
  • C09D179/02—Polyamines
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
  • C09D7/40—Additives
  • C09D7/60—Additives non-macromolecular
  • C09D7/63—Additives non-macromolecular organic
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/61—Polyamines polyimines
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2300/00—Characterised by the use of unspecified polymers
  • C08J2300/26—Elastomers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2203/00—Applications
  • C08L2203/12—Applications used for fibers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2205/00—Polymer mixtures characterised by other features
  • C08L2205/14—Polymer mixtures characterised by other features containing polymeric additives characterised by shape
  • C08L2205/16—Fibres; Fibrils
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
  • D06M2101/16—Synthetic fibres, other than mineral fibres
  • D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M2101/32—Polyesters
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
  • D06M2101/16—Synthetic fibres, other than mineral fibres
  • D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M2101/34—Polyamides

Definitions

• the present disclosure general ly relates to a coated fiber for polymer reinforcement and a method of producing the coated fiber.
• the present disclosure further relates to polymeric composites comprising the coated fiber.
• fillers to improve the physical a nd rheological properties of polymeric materials is known in the art.
• the addition of conductive filler to a polymer ca n impart conductivity on the resulting polymeric composite, despite the fact that the polymer alone would otherwise act as an insulator.
• the addition of reinforcing filler, e.g. a reinforcing fiber, to a polymer can impart improved load, creep, fatigue, strength, du ⁇ rability, a nd other properties on the resulting polymeric composite.
• the use of fillers in polymeric composites can be problematic.
• the loading of filler required to achieve polymeric composites having desirable physical and rheological properties can make processing, e.g.
• fil lers can be hard to disperse within a polymer ma ⁇ trix and, thus, conventional methods of com bining polymers and fibrous fillers often yield polymeric composites having inconsistent physical and rheological properties.
• fil lers e.g. fibrous fil lers
• costly processing adjustments e.g.
• formulary cha nges such as the incl usion of processing ad ⁇ ditives, are made to polymeric composites in an attempt to (1) produce polymeric compo- sites having consistent physical and rheological properties with conventional methods of combining polymers and fibrous fil lers, and (2) minimize the amount of fibrous fil ler re ⁇ quired to obta in polymeric composites having desirable physical and rheological properties.
• filler treatments such as the treatment of fi ⁇ brous fil lers with silanes, resorcinol-formaldehyde-latex (RFL) , isocyanate, epoxy, and/or ter-polymer lattices comprising vinyl pyridine has been employed to prevent delamination of fibrous fillers from the polymer within polymeric composites.
• RRL resorcinol-formaldehyde-latex
• isocyanate epoxy
• ter-polymer lattices comprising vinyl pyridine
• the instant disclosu re provides a coated fiber for polymer reinforcement, and polymeric composites including the coated fiber.
• the coated fiber comprises a fiber and a coating disposed about said fiber.
• the fiber has a denier of from about 250 to about 3,000.
• the coating comprises a branched polyethylene imine.
• the fiber is present in the coated fiber in an amount of from about 80 to about 99.8 percent by weight and the coating is present in the coated fiber in an amount of from about 0.2 to about 20 percent by weight, with percent by weight based on the total weight of the coated fiber.
• the instant disclosure also provides a method of producing the coated fiber.
• the method comprises the steps of providing the fiber, providing the coating, and applying the coating composition to the fiber to form the coated fiber.
• the coated fiber disclosed herein can be produced efficiently a nd disperses readily in vari ⁇ ous polymers. Because the coated fiber disperses readily in various polymers, the incl usion of the coated fiber in polymeric composites often yields polymeric com posites having desir- able physical and rheological properties. Further, conventional methods of combining poly ⁇ mers and the coated fiber can be used to produce polymeric composites having consistent physical and rheological properties.
• Figure 1 is an enlarged perspective cross-sectional view of a coated fiber com prising a sin ⁇ gle strand.
• Figure 2 is an enlarged perspective cross-sectional view of a coated fiber comprising 3 stands.
• Figure 3 is a surface topography image of Example Polymeric Composite 1 (which compris- es the coated fiber of Exam ple 1) taken against the machine direction on a Nanotronics nSpec 3D.
• Figure 4 is another surface topography image of Example Polymeric Composite 1 (which comprises the coated fiber of Exa mple 1) taken with the machine direction on a Nanotronics nSpec 3D.
• Figure 5 is a surface topography image of Example Polymeric Composite 2 (which compris ⁇ es the coated fiber of Exam ple 2) taken against the machine direction on a Nanotronics nSpec 3D.
• Figure 6 is another surface topogra phy image of Example Polymeric Composite 1 (which comprises the coated fiber of Exa mple 2) taken with the machine direction on a Nanotronics nSpec 3D.
• Figure 7 is a surface topography image of prior art Comparative Example Polymeric Compo ⁇ site 1 (which comprises the coated fiber of Comparative Example 1) taken against the ma ⁇ chine direction on a Na notronics nSpec 3D.
• Figure 8 is another surface topography image of prior art Compa rative Example Polymeric Composite 1 (which comprises the coated fiber of Comparative Example 1) taken with the machine direction on a Nanotronics nSpec 3D.
• Figure 9 is a surface topography image of Example Polymeric Composite 3 (which compris ⁇ es the coated fiber of Exam ple 3) taken against the machine direction on a Nanotronics nSpec 3D.
• Figure 10 is another surface topography image of Example Polymeric Composite 3 (which comprises the coated fiber of Exa mple 3) taken with the machine direction on a Nanotronics nSpec 3D.
• Figure 11 is a surface topography image of Example Polymeric Com posite 4 (which com ⁇ prises the coated fiber of Example 4) taken against the machine direction on a Nanotronics nSpec 3D.
• Figure 12 is another surface topography image of Example Polymeric Composite 4 (which comprises the coated fiber of Exa mple 4) taken with the machine direction on a Nanotronics nSpec 3D.
• Figure 13 is a surface topography image of prior art Comparative Example Polymeric Com- posite 2 (which comprises the coated fiber of Comparative Example 2) taken against the machine direction on a Nanotronics nSpec 3D.
• Figure 14 is another surface topography image of prior art Comparative Example Polymeric Composite 2 (which comprises the coated fiber of Comparative Example 2) taken with the machine direction on a Nanotronics nSpec 3D.
• Figures 1-14 are exemplary in nature, are not drawn to scale, and are thus not intended to represent the relative sizes of the various components of the coated fiber.
• the instant disclosure provides a coated fiber 10 for polymer reinforcement, and a polymer ⁇ ic composite 20 incl uding the coated fiber 10.
• the polymeric composite 20 can be used in a wide array of commercial and industrial products. In various embodiments, the polymeric composite 20 is used in tires, belts, conveyor belts, hoses, engine mounts, seals, gaskets, and other products. It is to be appreciated that the polymeric composite 20 of the subject disclosure can also be used in products not specifically set forth herein.
• the coated fiber 10 comprises a fiber 12 and a coating 14 disposed about said fiber 12.
• the terminology "disposed about” encompasses the coating 14 being dis ⁇ posed about the fiber 12 and a lso encompasses both partial and complete covering of the fiber 12 by the coating 14.
• the coating 14 is disposed about the fiber 12 to an extent suffi- cient to change the properties of the fiber 12, e.g. to provide the coated fiber 10 that can be efficiently and effectively dispersed in a polymer to form the polymeric composite 20 a nd, in some embodiments, to provide the coated fiber 10 which can crossl ink with a polymer 22 within the polymeric composite 20.
• a ny given sample of the coated fiber 10 typi- cally includes fibers 12 having the coating 14 disposed thereon, and the coating 14 is typi ⁇ cal ly disposed on a large enough surface area of each individua l fiber 12 so that the sample of the coated fiber 10 can be effectively incorporated into polymeric composites 20 having desirable properties.
• the coating 14 covers greater than about 30, greater than about 40, greater than about 50, greater tha n about 60, greater than about 70, greater tha n about 80, greater than about 90, greater tha n about 95, or greater than about 99, percent of a n outer peripheral surface of the fiber 12.
• all val ues and ranges of val ues, both whole and fractional, within one or more of the aforementioned rang- es are hereby expressly contemplated.
• the coated fiber 10 is cut to a desired length based on its end use (e.g. as in a polymeric composite 20 in a tire, a thermoplastic hose, etc.) .
• the coated fiber 10 has a length of from a bout 0.3 to about 25, about 0.5 to about 15, or about 3 to about 6, mm.
• the fiber 12 is selected from the group of polymeric fibers (e.g. acryl ic, polyam ide fibers, polyester fibers, polyolefin fibers, phenol-formaldehyde/novaloid fibers, etc.) , natural fibers (e.g. cell ulose fibers, l ignin fibers, rayon fibers, wood fibers, etc.), glass fibers (e.g. E-glass, A-glass, E-CR-glass, C-glass, D-glass, S-glass, etc.) , ceramic fi ⁇ bers, metal lic fibers (e.g. stainless steel , aluminum, etc.) , carbon and carbon composite fi ⁇ bers, (e.g.
• polymeric fibers e.g. acryl ic, polyam ide fibers, polyester fibers, polyolefin fibers, phenol-formaldehyde/novaloid fibers, etc.
• natural fibers e.g. cell ulose fibers, l ignin
• the fibers are composite or multi component fibers comprising any combination of suitable materials set for herein (polymer, metal, mineral , etc.). Examples of such compo ⁇ site fibers include n ickel coated carbon fiber, silver coated fibers, and coextruded polymer fibers.
• the fiber 12 is selected from the group of acrylic fibers, polyamide fibers, polyester fibers, polyolefin fibers, cel lulose fibers, glass fibers, ceramic fibers, novoloid (phenol-formaldehyde) fibers, carbon fibers, mineral fibers, metal fibers, composite fibers comprising at least one of the aforementioned materials, and combina- tions thereof.
• the fiber 12 comprises, consists essentially of, or consists of glass.
• the glass is further defined as E-glass fibers (alumino- borosil icate glass with less than 1% w/w alkal i oxides, A-glass (Al kal i-lime glass with little or no boron oxide), E-CR-glass (Electrical/Chemical Resistance; alu mino-lime sil icate with less than 1% w/w alkali oxides, with high acid resistance), C-glass (alkali-lime glass with high boron oxide content, used for glass staple fibers and insulation), D-glass (borosilicate glass, named for its low Dielectric constant), R-glass (alumino silicate glass without MgO and CaO with high mechanical requirements as reinforcement), and S-glass (alumino sili- cate glass without CaO but with high MgO content with high tensile strength).
• E-glass fibers alumino- borosil icate glass
• the fiber 12 comprises, consists essentially of, or consists of a poly ⁇ mer 22.
• the polymer 22 can be any polymer known in the art and can be produced in any way known in the art, e.g. wet spinning, hot extrusion, etc.
• the polymer is selected from polyamide, polyester, polyolefin, ther ⁇ moplastic polyurethane (TPU), Poly (vinyl alcohol) (e.g. PVOH, PVA, or PVAI), polyolefins (e.g. polyethylene (PE), ultra high molecular weight PE (UHMWPE), polypropylene (PP)), and combination thereof.
• the fiber 12 comprises, consists essentially of, or consists of a poly ⁇ amide fiber.
• the polyamide may be defined as the polymer 22 comprising repeating amide, -CO-NH-, linkages.
• the polyamide may be a homopolymer (e.g. nylon 6) or a co-polymer (e.g. nylon 6,6, nylon 6/66).
• copolymers include two or more different monomers.
• the polyamide can be an aliphatic, e.g. nylon, or aromatic polyamide, e.g. aramid. In some embodiments, the polyamide is a meta-aramid. In other embodiments, the polyamide is a para-aramid.
• Aramid fibers are a class of heat-resistant and strong synthetic fibers. In var- ious embodiments, the terminology "consists essentially of" describes the polyamide itself as only a single compound, two compounds, three compounds, etc., and may be free of any other polyamides or compounds.
• the polyamide may be or include, consist essentially of, or consist of one or more nylons, aramids, proteins, metal poly(aspartates) such as sodium poly(aspartate), and com ⁇ binations thereof.
• the polyamide is an aliphatic or semi-aromatic polyamide such as nylon.
• Nylons are condensation copolymers typically formed by reacting diamines and di- carboxylic acids to form peptide bonds.
• the nylon is further defined as having less than about 85 percent of amide-linkages attached directly (-CO-NH-) to two aliphatic groups.
• the polyamide may be or include, consist essentially of, or consist of one or more of polyamide 6, polyamide 6,6, polyamide 6/66, polyamide 10/10, polyamide 10/12, poly(4-aminobutyric acid) (nylon 4), poly(7-aminoheptanoic acid) (nylon 7), poly(8-aminooctanoic acid)(nylon 8), poly(9-aminononanoic acid) (nylon 9), poly(10- aminodecanoic acid) (nylon 10), poly(ll-aminoundecanoic acid) (nylon 11), poly(12- aminododecanoic acid) (nylon 12), nylon 4,6, poly(hexamethylene sebacamide) (nylon 6,10), poly(heptamethylene pimelamide) (nylon 7,7), poly(octamethylene suberamide) (nylon 8,8), poly(hexamethylene azelamide) (nylon 6,9), poly(nonamethylene azelamide) (n), nylon
• poly(tetramethylenediamine-co-isophthalic acid) (nylon 4,1) , polyhexamethylene isophthalamide (nylon 6,1) , hexamethylene adipa mide/hexa methylene-isophthalamide (ny ⁇ lon 6,6/61), hexamethylene adipam ide/hexamethyleneterephthala mide (nylon 6,6/6T) , poly (2,2,2-trimethylhexamethylene terephthalamide) , poly(m-xylylene adipamide) (MXD6) , poly(p-xylylene adipamide), poly(hexamethylene terephthalamide) , poly(dodecamethylene terephthalamide) , polyamide 6T/6 I, polyamide 6/MXDT/l, polyamide MXDI , a terpolymer of lauryl lactam, isophthalic acid and bis(4-amino-3-methylcyclo
• the polyamide is chosen from polyamide 6, polyamide 6,6, polyamide 6/66, and combinations thereof.
• the polyamide is chosen from polyamide 6, polyamide 6,6, polyam ide 6/66, poly- amide 12, polyamide 11 , polyamide 6/10, polyamide 6/6.36, polya mide 6I/6T, and combina ⁇ tions thereof.
• the polyamide is an aromatic polya mide, i.e., aramid.
• Aramids are typically formed by reacting amines and carboxylic acid halides.
• the ara mid is further defined as having at least about 85 percent of amide linkages (-CO- N H-) attached directly to two aromatic rings.
• the aramid may be any known in the art, but is typically further defined as a n AABB polymer, sold u nder tradenames such as Nomex * , Kevlar * , Twaron * and/or New Star TM .
• the polyamide has a weight average molecular weight of greater than about 10,000, or greater than about 25,000, or from about 10,000 to about 1,000,000, or from a bout 50,000 to about 750,000, or from about 25,000 to about 500,000, g/mol.
• the fiber 12 comprises, consists essentially of, or consists of a pol ⁇ yester fiber.
• the polyester may be defined as a polymer comprising repeating ester func- tional groups (esters). I n other words, several esters are linked within polyester. Typically, alcohol is chemically reacted with carboxylic acid results to form the esters.
• the polyester may be defined as a polymer comprising at least about 85 percent by weight of an ester, a dihydric alcohol, a terephthal ic acid.
• the polyester may be a homopolymer or a co-polymer. I n some embodiments, the polyester is an aliphatic polyester.
• Suitable aliphat ⁇ ic polyesters include, but are not l imited to, homopolymers such as polyglycol ide or polygly- colic acid (typically formed via polycondensation of glycolic acid) , polylactic acid (typically formed via ring-opening polymerization of lactide) , polycaprolactone (typically formed via ring-opening polymerization of ca prolactone) , polyhydroxyal kanoate, and polyhydroxybutyr- ate.
• homopolymers such as polyglycol ide or polygly- colic acid (typically formed via polycondensation of glycolic acid) , polylactic acid (typically formed via ring-opening polymerization of lactide) , polycaprolactone (typically formed via ring-opening polymerization of ca prolactone) , polyhydroxyal kanoate, and polyhydroxybutyr- ate.
• suitable al iphatic polyesters incl ude are not limited to, copolymers such as polyethylene adipate, polybutylene succinate (typically formed via polycondensation of succinic acid with 1,4-butanediol), a nd poly(3-hydroxybutyrate-co-3-hydroxyvalerate (typically formed via copolymerization of 3-hydroxybutanoic acid and 3-hydroxypentanoic acid, butyrolactone, valerolactone with ol igomeric aluminoxane as a catalyst) , and polycy- clohexylenedimethylene terephthalate (typically formed via formed from the polycondensa ⁇ tion of terephthal ic acid and cyclohexylene-dimethanol).
• copolymers such as polyethylene adipate, polybutylene succinate (typically formed via polycondensation of succinic acid with 1,4-butanediol), a
• the polyester is an aromatic polyester such as vectranTM (typically formed via polycondensation of 4-hydroxybenzoic acid and 6-hydroxynaphthalene-2- carboxylic acid) .
• vectranTM typically formed via polycondensation of 4-hydroxybenzoic acid and 6-hydroxynaphthalene-2- carboxylic acid
• the polyester is a semi-aromatic polyester.
• suitable al iphatic polyesters include, but are not l imited to, copolymers such as polyethylene tereph- thalate (typically formed via polycondensation of terephthalic acid with ethylene glycol) , polybutylene terephthalate (typically formed via polycondensation of terephthalic acid with 1,4-butanediol) , polytrimethylene terephthalate (typically formed via, polycondensation of terephthal ic acid with 1,3-propanediol) , and polyethylene naphthalate (typically formed via polycondensation of at least one naphthalene dicarboxyl ic acid with ethylene glycol).
• the polyester can be selected from a polyalkylene tereph ⁇ thalate such as polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, polyethylene adipate, polyhydroxylalkanoate, poly- hydroxyl butyrate, poly(3-hydroxybutyrate-co-3-hydroxyvalerate) , polyglycolide, polylactic acid, the polycondensation product of 4-hydroxybenzoic acid and 6-hydroxynaphthalene-2- carboxyl ic acid, and polycaprolactone.
• a polyalkylene tereph ⁇ thalate such as polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, polyethylene adipate, polyhydroxylalkanoate, poly- hydroxyl butyrate, poly(3-hydroxybutyrate-co-3-hydroxyvalerate) , polyglycoli
• the polymer 22 is fur ⁇ ther defined as a sem i-crystall ine thermoplastic polyester incl uding, but not l imited to, poly ⁇ ethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyeth ⁇ ylene terephthalate-co-isophthalate, and com binations thereof.
• the polymer 22 is polybutylene terephthalate.
• the polymer 22 is polyethylene naphthalate.
• the fiber 12 is further defined as comprising from about 2 to about 8, or from about 2 to about 4, ends or strands.
• an "end" is a single strand comprising one or more filaments.
• the fiber 12 is bul k con ⁇ tinuous fila ment or staple.
• the fiber 12 can be drawn or non-woven.
• the fiber 12 is woven or braided.
• the yarn can comprise ends of one materia l (e.g. just polyamide ends) or ends of more than one material (e.g. both polyamide and polyester ends) .
• the fiber 12 can be mono-end , multi-end, or staple yarn.
• Figure 1 is an enlarged cross-sectional view of a coated fiber 10 comprising a single stra nd and Figure 2 is an enlarged cross-sectional view of a coated fiber 10 comprising 3 strands.
• the coated fiber 10 can comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, or more ends or strands.
• the fibers 12 shown in Figures 1 and 2 have a round cross-sectional profile, it is to be appreciated that the fibers 12 can have cross-sectional profiles of various sha pes, such as round, ovular, triangular, rectangular, square, 5 sided, 6-sided, bell-shaped, star-shaped, bi-lobal, tri-lobal, flattened, etc. I n some embodiments, the fibers are hollow.
• the fiber 12 has: a denier of from about 250 to about 3,000, from about 1,000 to about 2,500, or from about 1,400 to a bout 2,100; and/or a diameter of from about 0.1 to about 15, from about 0.3 to about 7.5, or from about 0.5 to about 3, ⁇ .
• denier is the mass in grams per 9,000 meters of the fiber 12.
• the fiber 12 is present in the coated fiber 10 in an amount of from about 80 to about 99.8, about 90 to about 99.8, about 90 to about 99, about 92 to about 99, or about 93 to about 97, percent by weight based on the total weight of the coated fiber 10.
• all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contem ⁇ plated.
• the coated fiber 10 comprises the coating 14, which is disposed about the fiber 12.
• the coating 14 comprises a polyethylene imine (PEI) .
• the PEI can be made by various methods understood in the art.
• the PEI can be made by ring opening of aziridine by acid catalyzed polymerization.
• the PEI can be further modified, such as by amidation with fatty acids, by alkoxyla- tion with al kylene oxides, or by carboxylation with acrylic acid and/or maleic acid.
• the PEI has a weight average molecular weight (M w ) of from about 300 to about 2,000,000, about 400 to about 1,000,000, about 500 to about 900,000, about 800 to about 800,000, about 800 to about 25,000, g/mol .
• the PEI is a branched polymer comprising groups such as:
• n is about 18 to about 50,000 such that the PEI has a weight average molecular weight of about 800 to about 2,000,000 g/mol. It is also contemplated that the PEI may have any val ue or range of values, both whole and fractional , within those ranges described above. I n still other embodiments, the PEI is a branched polymer having the following ex ⁇ emplary structure:
• the bra nched structure of the PEI provides primary, secondary, and tertiary amines. That is, the PEI typical ly includes linear (L), den- dric (D) , and terminal groups (T) .
• the branched polyethylene imine comprises: from about 20 to about 55, or from about 30 to about 45, percent l inear groups (L) ; from about 10 to about 40, or from a bout 20 to about 30, dendric groups (D); and from a bout 20 to about 55, or from about 30 to about 45, percent terminal groups (T), based on 100 percent of al l groups present in said branched polyethylene imine as determined via 13 C- N M R in D 2 0.
• all values and ranges of values, both whole and fractional , within one or more of the aforementioned ra nges are hereby expressly contemplated.
• the branched structure of the PEI incl udes primary, secondary and ter ⁇ tiary amines.
• Table 1 sets forth four exemplary embodiments of PEI that can be incl uded in a coating composition and used to form the coating 14.
• the PEI embodiments set forth in Table 1 are non-l imiting embodiments and, thus, other PEI embodiments of alkyl amine with different physical characteristics are also contemplated.
• the coating composition may include water.
• the water evaporates from the coating composition, the coating 14 is formed.
• This water may be the same as, or inde ⁇ pendent from, the water described immediately above which is mixed with the PEI .
• the water can be of various types. I n certain embodiments, the water is de-mineral ized and/or de-ionized.
• the water is present in the coating composition in various amounts, depending on the embodiment.
• the water can be added to the coating com position as a separate component.
• Suitable PEI's are commercial ly available from BAS F Corporation under the trade name of LU PASO L".
• the PEI is present in the coating 14 in an amount of from a bout 80 to about 100, about 90 to about 99.5, or a bout 92 to about 99, percent by weight based on the total weight of the coating 14.
• more than one type of PEI may be included in the coating 14 (e.g. two different molecular weight PEI 's) , in which case the total a mount of all PEI present in the coating 14 is within the above ranges.
• al l values and ranges of val ues, both whole and frac ⁇ tional, within one or more of the aforementioned ranges are hereby expressly contemplat ⁇ ed.
• the coating 14 may also include one or more surfacta nts.
• the surfactant is included to im ⁇ prove the wetting and/or lower the surface tension of the coating composition. If employed, the surfactant is typically selected from the group of nonionic surfactants, anionic surfac ⁇ tants, cationic surfactants, amphoteric surfactants, and combinations thereof.
• the surfactant is selected from the group of polyalkyleneoxide, alkyl poly- al kyleneoxide, polyoxyethylene sorbitan monolaurate, alkylpolygl ucosides, anionic deriva ⁇ tives of al kylpolyglucosides, fatty alcohols, anionic derivatives of fatty alcohols, and phos ⁇ phate esters.
• the coating 14 includes a non-ionic su rfactant.
• Non-ionic surfac ⁇ tants suitable for purposes of the present disclosure, include alcohol al koxylates, e.g. poly- al kyleneoxides.
• Suitable a lcohol alkoxylates include l inear alcohol ethoxylates.
• Additional alcohol alkoxylates include alkylphenol ethoxylates, branched alcohol ethoxylates, second ⁇ ary alcohol ethoxylates, castor oil ethoxylates, alkylamine ethoxylates (also known as alkox- ylated alkyl amines), tallow amine ethoxylates, fatty acid ethoxylates, sorbital oleate ethox ⁇ ylates, end-capped ethoxylates, or combinations thereof.
• non-ionic surfactants in ⁇ cl ude amides such as fatty al kanolamides, alkyldiethanolamides, coconut dietha nolamide, lauramide diethanolamide, cocoamide diethanolamide, polyethylene glycol cocoamide, oleic diethanolamide, or combinations thereof.
• non-ionic surfactants include poly- al koxylated aliphatic base, polyalkoxylated am ide, glycol esters, glycerol esters, amine ox ⁇ ides, phosphate esters, alcohol phosphate, fatty triglycerides, fatty triglyceride esters, al kyl ether phosphate, al kyl esters, alkyl phenol ethoxylate phosphate esters, al kyl polysaccha ⁇ rides, block copolymers, alkyl polygl ucocides, or combinations thereof.
• Suitable non-ionic surfactants are commercially available from BASF Corporation under the trade na mes of PLU RAFAC", PLU RO N IC", TETRO N IC", and LUTENSO L".
• the coating 14 includes an amphoteric surfactant.
• Amphoteric sur ⁇ factants suitable for purposes of the present disclosure, incl ude betaines, imidazolines, and propionates.
• suitable amphoteric surfactants include sultaines, am- phopropionates, amphrodipropionates, aminopropionates, aminodipropionates, amphoace- tates, amphodiacetates, and amphohydroxypropylsulfonates.
• the amphoteric surfactant is at least one of a propionate or an amphodiacetate.
• amphoteric surfactant is illustrated by the formulas:
• M is a salt-forming cation (e.g. Na or H) and R is the hydrocarbon moiety of the long-chain fatty acid RCOO H , e.g. a C 7 to C 35 , or a C 7 to C 18 , fatty acid.
• Such a mphoteric surfactants include sodium N-coco- 3 - aminopropionate, N-coco- 3 amino propionic acid; N-lauryl , myristyl- 3 -amino propionic acid; disodium N -tallow- S -iminopropionate; disodium N-lauryl- 3 -iminopropionate (also known as sodium la uriminodipropionate); and the partial sodium salt of N-lauryl- /3 - iminopropionic acid.
• the amphoteric surfactant comprises sodium la u ⁇ riminodipropionate.
• Suitable amphoteric surfactants are commercially available from BASF Corporation, under the trade na mes of D ERI PHAT", MAFCT, and DEHYTO N". I n many em bodiments, the surfactant(s) is present in the coating 14 in an amount of from about 0.1 to about 9, about 0.2 to about 6, or about 0.3 to about 3, percent by weight based on the total weight of the coating 14. Further, it is to be appreciated that more than one type of surfactant may be incl uded in the coating 14 (e.g. both a polyalkyleneoxide and a fatty alcohol), in which case the total amount of all surfactant present in the coating 14 is within the above ra nges. In additional non-limiting embodiments, al l val ues and ranges of val ues, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.
• the coating 14 further comprises one or more additives.
• additives can be used. Examples of suitable additives include antioxidants, che- lants, colorants, dispersants, stabilizers, viscosity modifiers, fillers, crossl inkers/curatives, catalysts, blowing agents, and combinations thereof. If utilized, the additive(s) may be used in various a mounts.
• the coating 14 further comprises a resorcinol-formaldehyde-latex (RFL) and/or isocyanate.
• RTL resorcinol-formaldehyde-latex
• the coating 14 is substantially free of resorcinol-formaldehyde-latex and/or isocyanate.
• substantially free of resorcinol-formaldehyde-latex and/or isocyanate refers to an amount of less than about 5, less than a bout 1, less than about 0.1, percent by weight based on the total weight of the coating 14 present in the coated fiber 10.
• the coating 14 consists essentially of the branched PEI and the sur ⁇ factant.
• “consisting essentia lly of” is meant to exclude any element or combination of elements, as well as any amount of any element or combination of elements, that would alter the basic and novel characteristics of the polya mide composition.
• the coating 14 is substantia lly free from other polymers known in the art (incl uding elastomers) , fillers known in the art (incl uding reinforcing fillers) , and/or plas- ticizers known in the art.
• the coating 14 is present in the coated fiber 10 in an a mount of from about 0.2 to about 10, about 1 to about 8, or about 3 to about 6, percent by weight based on the total weight of the coated fiber 10.
• the coated fiber 10 comprises additional adhesive com ponents.
• the adhesive component ca n be included in the coating 14 or applied separately to the coated fiber 10 (e.g. as an additional layer between the fiber 12 a nd the coating 14 or as an additional layer on top of the coating 14).
• suitable non-l imiting exa mples of suitable adhesives comprise polymers such as ethylene vinyl acetate copolymers, ethylene acrylate copoly- mers, (meth)acrylates, polyolefins (e.g.
• polyethylene H DPE, LDPE, etc.
• polypropylene polybutene-1, oxidized polyethylene, polybutene, amorphous polyolefins (amorphous pro ⁇ pylene, amorphous propylene/ethylene, a morphous propylene/butene, amorphous propyl- ene/hexene, amorphous propylene/ethylene/butene, etc.), chlorinated polyolefins (chlorin ⁇ ated polypropylene) , maleic an hydride modified polyolefins), polya mides and polyesters, polyesters, polyuretha nes (TPU , PU R, etc.) , styrene block copolymers (styrene-butadiene- styrene, styrene-isoprene-styrene, styrene-ethylene/butylene-styrene, s
• the adhesive component comprises or is a resorcinol-formaldehyde- latex (RFL) adhesive.
• RFL resorcinol-formaldehyde- latex
• the resorcinol reacts with formaldehyde to pro ⁇ prise a resorcinol-formaldehyde reaction product.
• This reaction product is the result of a condensation reaction between a phenol group on the resorcinol and the aldehyde group on the formaldehyde.
• Resorcinol resoles and resorcinol-phenol resoles are typical ly incl uded in the RFL adhesive/adhesive layer to facilitate rubber adhesion of further layers/components.
• the RFL adhesive comprises a resorcinol formaldehyde resin, a styrene-butadiene copolymer latex, a vinyl pyridine-styrene-butadiene terpolymer latex, and a blocked isocyanate.
• the RFL adhesive comprises a resorcinol, formaldehyde, a styrene-butadiene rubber latex, a vinylpyridine-styrene-butadiene terpoly ⁇ mer latex, and a blocked isocyanate.
• the coated fiber 10 comprises a supplementary coating comprising an RFL adhesive.
• the supplementary coating can be disposed between the fiber 12 and the coating 14 (e.g. about an outer peripheral surface of the fiber 12 a nd an in ⁇ ner peripheral surface of the coating 14) or can be disposed about an outer peripheral sur ⁇ face of the coating 14, i.e. as an outer coating.
• the adhesive component comprises or is an isocyanate.
• the isocyanate incl udes but is not limited to, isocyanates, diisocya- nates, polyisocyanates, and com binations thereof.
• the isocyanate component can include one or more different isocyanates. I n one embodiment, the isocyanate component incl udes an n-functional isocyanate.
• n is a number from about 2 to about 5, about 2 to about 4, about 2 to about 3, or about 2. It is to be understood that n may be an integer or may have intermediate values from a bout 2 to about 5.
• the isocyanate typical ly includes an isocyanate selected from the group of aromatic isocyanates, al iphatic isocya ⁇ nates, and combinations thereof.
• the isocyanate component in- el udes an al iphatic isocyanate such as hexamethylene diisocyanate (H DI) , dicyclohexyl- methyl-diisocyanate (H 12M DI), isophoron-diisocyanate, and com binations thereof.
• the isocyanate component may also include a modified multivalent aliphatic isocyanate, i.e., a product which is obta ined through chem ical reactions of aliphatic diisocyanates and/or aliphatic polyisocyanates.
• a modified multivalent aliphatic isocyanate i.e., a product which is obta ined through chem ical reactions of aliphatic diisocyanates and/or aliphatic polyisocyanates. Examples include, but are not limited to, ureas, biurets, allophanates, carbodiimides, uretonim ines, isocyanurates, urethane groups, dimers, trimers, and combinations thereof.
• the isocyanate may also include, but is not limited to, modified diisocyanates employed individually or in reaction products with polyoxyal kyleneglycols, diethylene glycols, dipropylene glycols, poly- oxyethylene glycols, polyoxypropylene glycols, polyoxypropylenepolyoxethylene glycols, pol- yesterols, polycaprolactones, and combinations thereof.
• the isocyanate may also be an isocyanate prepolymer.
• the coated fiber 10 is free of or substantially free from adhesive components known in the art.
• substantially free refers to an amount of less than about 5, less than about 1, less than about 0.1, or about 0, percent by weight adhesive component based on the total weight of the coated fiber 10.
• the instant disclosure also provides a method of producing the coated fiber 10.
• the meth ⁇ od comprises the steps of providing the fiber 12, providing the coating composition, and applying the coating composition to the fiber 12 to form the coated fiber 10.
• the fiber 12, the coating 14, and the coated fiber 10 are just as described above.
• the coated fiber 10 is a yarn comprising two or more ends.
• the method incl udes the step of braiding one or more ends on bra iding equipment with from about 1 to about 12 carriers/bobbins.
• the braids can comprise any combination of ends.
• the step of applying is con- ducted in-line with the step of applying the coating composition.
• the method also comprises the step of applying the coating composition to the fiber 12 to form the coated fiber 10.
• the coating composition may include water and/or curatives. When the water evaporates and/or the curatives cure the PEI , the coating 14 is formed.
• the step of applying the coating composition to the fiber 12 to form the coated fiber 10 is typical ly conducted via spraying, brushing, immersion, or other methods known in the art. I n a preferred embodiment, the step of applying is conducted via immersion. In various embodiments, the step of applying is conducted in less than about 10, about 9, about 8, about 7, about 6, about 5, about 4, about 3, about 2, or about 1, seconds.
• the coated fiber 10 comprises, consists essentially of, or con ⁇ sists of the fiber 12 and the coating 14 and the method includes a single appl ication of the coating composition, i.e. a single layer of coating.
• Methods of the prior art often utilize multiple adhesive com ponents (e.g. isocyanate and RFL) and, thus, require multiple a pplica- tions of coatings since multiple adhesive components are required and since the adhesive components may react with one a nother (e.g. isocyanate react with RFL).
• a single appl ication of the coating composition of the subject application can be used in lieu of m ultiple applications of other coating compositions.
• the fiber 12 has a surface energy of from about 30 to about 60 mJ/m 2 and the composition has a surface tension of from about 20 to about 65 J/m 2 , which enables a single application step.
• the surface tension of the coating composi ⁇ tion can be adjusted to facilitate the wetting of the particula r fibers 12 (e.g. aramid vs. poly ⁇ ester) selected for incorporation in the coated fiber 10.
• the coating com position (comprising PEI) is first ap ⁇ pl ied to an outer peripheral surface of the fiber 12 and then the adhesive component com ⁇ prising RFL is subsequently applied to the coating 14.
• the adhesive component comprising RFL is first applied to an outer peripheral surface of the fiber 12 and then the coating composition is subsequently appl ied to the adhesive com ⁇ ponent comprising RFL.
• the method optionally includes the step of heating the fiber 12 having the coating composi ⁇ tion thereon subsequent to the step of applying the coating composition.
• the step of heat- ing is typical ly conducted subsequent to the step of applying.
• the step of heating ca n be included in various embodiments of the method one or more times, i.e., the method can incl ude one or more heating steps.
• the fiber 12 having the coat ⁇ ing composition thereon can be dried at any suitable drying tem perature. I n some embodi ⁇ ments, the fiber 12 having the coating composition thereon is heated to a temperature of from a bout 35 to about 250, about 50 to about 200, or about 75 to about 125, ° C.
• the Polymeric Com posite Referring to the Figures 5-14, wherein l ike n umerals indicate corresponding parts throughout the several views, the polymeric composite is generally shown at 20.
• the polymeric composite 20 incl udes the coated fiber 10 and a polymer 22.
• the coated fiber 10 is just as described above and can be included in the polymeric compo- site 20 in an a mount of from about 0.5 to about 65, about 1 to about 45, about 2 to about 25, about 2 to 15, or about 2 to about 10, percent by weight based on the total weight of the polymeric composite 20.
• al l val ues and ra nges of val ues, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.
• the polymeric composite 20 comprises one or more of the polymer 22.
• the polymer 22 is selected from elastomers, thermoplastics, thermoplastic elastomers, and combinations thereof.
• the polymer 22 can be a thermoplastic polymer or a thermosetting polymer.
• Thermoplastics have a relatively high molecular weight and molecular chains that associate through intermolecular forces, which weaken rapidly with increased tem perature, and, thus, melt.
• thermoplastics may be reshaped by heating and are typical ly used to produce parts by various polymer-processing techniques such as injection molding, compression molding, calendering, and extrusion.
• thermosets form irreversible chemical bonds when cured and, thus, do not melt, but decompose.
• the polymer 22 is a thermoplastic polymer (thermoplastic) .
• the thermoplastic can be an amorphous or crystall ine polymer.
• crystalline polymers have a relatively sharp melting point, have a more ordered arrangement of molecular chains, and require higher temperatures to flow well when compared to amorphous polymers.
• Gen ⁇ erally, amorphous polymers have no true melting point and soften gradually, have a more random orientation of molecular chains, and do not flow as easily as amorphous polymers.
• thermoplastics and thermoplastic elastomers in- el ude polyolefins e.g. PP, PE, ethylene/hexa ne copolymer, ethylene/acrylic acid, etc.
• pol- yolefin elastomers polyvinylchlorides (PVC) , polyamides (PA) , styren ic elastomers, thermo ⁇ plastic vulcanate elastomer (TPV) , fluoropolymers (e.g.
• the polymer 22 is selected from thermoplastic polyurethane, polyoxymethylene, polyal kylene terephthalate, and combinations thereof.
• the polymer is an elastomer (rubber) .
• elastomers include natural rubber (natural polyisoprene) , synthetic polyisoprene, polybutadiene, chloroprene rubber, butyl rubber, halogenated butyl rubber, styrene-butadiene rubber, nitrile rubber, ethylene propylene ru bber, ethylene propylene diene rubber (EPD M) , epichlorohydrin rubber, polyacryl ic rubber, sil icone rubber, fluorosil i- cone rubber, fluoroelastomer, perfluoroelastomer, polyether block amides, chlorosulfonated polyethylene, and ethylene-vinyl acetate.
• the polymer 22 is included in the polymeric composite 20 in an amount of from about 5 to about 95, about 20 to about 90, about 30 to about 80, or about 40 to about 70, percent by weight based on the total weight of the polymeric composite 20. Further, it is to be appreciated that more tha n one type of polymer may be included in the polymeric composite 20 (e.g. two different polymers) , in which case the total amount of al l polymers present in the polymeric composite 20 is within the above ranges. I n additional non-limiting embodiments, all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated. Various additives can be included in the polymeric composite 20.
• Suitable additives incl ude are not limited to, processing additives, plasticizers, cha in terminators, surface-active agents, adhesion promoters, flame retardants, anti-oxidants, water scavengers, dyes, ultra ⁇ violet l ight sta bilizers, fil lers, acidifiers, thixotropic agents, curatives/cross-linkers, catalysts, blowing agents, surfactants, and combinations thereof.
• the additive(s) may be incl uded in any amount as desired by those of skill in the art.
• the polymeric composite 20 is incorporated into belts (e.g V-belts), hoses, tires, and other products.
• V-belts are rubber belts, usually endless, with a trapezoi ⁇ dal cross section which runs in a pu lley with a V-shaped groove, with the top surface of the belt approximately flush with the top of the pulley, which are used in many different appli ⁇ cations.
• Incorporation of the polymeric composite 20 may be accom plished using methods as are known in the art.
• Example Coated Fibers 1-4 which are set forth in Table 2 below, are in accordance with the subject disclosure.
• X coating composition applied via im mersion, and then dried to form coating.
• Fiber A is a polyester fiber comprising three ends twisted into one and having a denier of about 2000.
• Fiber B is a polyamide fiber comprising two ends twisted into one and having a denier of about 1500.
• Coating Composition A comprises about 5 percent by weight of a branched polyethylene imine, a bout 0.5 percent by weight of a surfactant, and about 94.5 percent by weight sol- vent, based on the total weight of the coating composition.
• Coating Composition B comprises about 10 percent by weight isocyanate and about 90 per ⁇ cent by weight solvent, based on the total weight of the coating composition.
• Coating C comprises about 20 percent by weight resorcinol formaldehyde latex (RFL) and about 80 percent by weight solvent, based on the total weight of the coating com position.
• the coated fibers of Examples 1-4 and Comparative Examples 1 and 2 are cut to a length of 3 m m. Once cut, the coated fibers of Examples 1-4 and Comparative Examples 1 and 2 are compounded into an elastomeric/ru bber based belt form ulation to form Polymeric Compo ⁇ sites ("PC") 1-4 and Comparative PC 1 and 2.
• PC Polymeric Compo ⁇ sites
• the amount and type of each component included in PC 1-4 and Comparative PC 1 and 2 is indicated in Table 3 below with al l val ues in parts per hundred rubber. All of the components except for the accelerator and curative are first compounded for about 3 min utes in a conventional rubber mixer with a conventional mixing procedure to form a base material .
• This "first pass" mixing procedure is initiated at a starting tempera ⁇ tu re of 38° C (100° F) and a starting rotor speed of 65 to 75 RPM .
• This first-pass mixing procedu re utilizes sweeps at 82° C (180° F), 93° C (200° F), and 110° C (230° F) , with a dump at about 137° C (280° F).
• Curative and accelerator are added to the PC 1-4 and Comparative PC 1 and 2 are then compounded for about 1.3 minutes at a lower temperature in a conventional rubber mixer with a conventional mixing procedure to form PC 1-4 and Comparative PC 1 and 2.
• This "second pass” mixing procedure is initiated at a starting temperature of 38° C (100° F) and a starting rotor speed of 65 to 75 RPM.
• This "first-pass” mixing procedure utilizes a single sweep at 82° C (180° F) with a dump at about 99° C (210° F).
• Table 3 the amount and type of each component included in PC 1- and Compa rative PC 1 and 2 is indicated with al l values in parts per hundred rubber, and the processing para meters utilized in the compounding process are set forth.
• Polymer A is EPDM .
• Filler A is carbon black.
• Additive A is paraffinic oil.
• Additive B is zinc oxide.
• Additive C is an antioxida nt comprising 4, 4'- Bis (alpha, al pha-dimethylbenzyl) diphenyla- mine.
• Additive D is an antioxida nt com prising zinc 2-mercaptotol umidazole.
• Additive E is an accelerator comprising N ,N'-1,3-Phenylene bismaleimide.
• Additive F is a curative comprising dicumyl peroxide.
• PC 1 and PC 2 require less mix time and power utilization than Comparative PC 1. I n fact, PC 2 mixes in the least time, and utilizes the lowest amount of energy of PCI, PC 2, and Com pa rative PC 1, all of which util ize coated polyether fibers. As such, the coated fibers of PC 1 and PC 2 (Examples 1 and 2 incl uding the branched PEI) are efficiently processed to yield excellent dispersion.
• PC 3 and PC 4 require similar mix times and power horrin ⁇ tion with Comparative PC 2.
• the coated fibers of PC 3 and PC 4 (Exa mples 3 and 4 including the branched PEI) are efficiently processed to yield excellent dispersion.
• PC 1-4 and Comparative PC 1 and 2 are tested for:
• Viscosity is a good indication for how a com ⁇ pound wil l process on a mill, calendar or in an injection or transfer mold (ASTM D1646-15/Monsanto MV 2000 Viscometer/100° C
• Tc50 The time it takes for a compound to reach 50 percent of its total state of cure or crosslinks.
• Tc90 The time it takes for a compound to reach 90 percent of its total state of cure or crosslinks.
• Ts2 The time it takes for the viscosity to rise 2 points over the M inim um Torque (M L) value. This is an indication of the time it ta kes for the compound to begin curing up at the specified tem ⁇ perature. Ts2 can indicate compound shelf life and stability and can help determine if you have enough time to injection or transfer mold. (ASTM D5289-12/Tech Pro RheoTECH M DR/170° C
• Pea k Tensile Strength The maxim um force a rubber compound can withstand while being stretched before brea king (ASTM D412-15a, D2240-15) ;
• Elongation at Break The length at the breaking point expressed as a percentage of its original length (ASTM D412-15a, D2240-15);
• PC 1-4 exhibit excellent physical properties.
• PC 1 and PC 3 which incl ude the fibers of Exa mples 1 and 2 incl uding the branched PEI , perform particularly well relative to the other polymeric composites.
• the colored images are the 3D models of the su rface.
• PCI, PC 2, and Comparative PC 2 are cut and a surface analysis is performed on a Nanotronics nSpec 3D at the settings set forth above.
• the coat- ed fibers of PC 3 and PC 4 (including Exam ples 3 and 4 incl uding the branched PEI) are ef ⁇ ficiently processed to yield excel lent dispersion.
• a nd are understood to describe and contemplate all ranges including whole a nd/or fractional values therein, even if such values are not expressly written herein.
• One of skil l in the art readily recognizes that the enu merated ranges and subranges suffi ⁇ ciently describe and enable various embodiments of the present disclosure, and such rang- es and subranges may be further delineated into relevant halves, thirds, quarters, fifths, and so on.
• a range of “at least 10" inherently incl udes a subrange of from at least 10 to 35, a subrange of from at least 10 to 25, a subrange of from 25 to 35, and so on, and each subrange may be relied upon indi ⁇ vidua lly and/or collectively and provides adequate support for specific embodiments within the scope of the appended claims.
• an individual number within a disclosed range may be relied upon a nd provides adequate support for specific embodiments within the scope of the appended claims.

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